Automotive lamp peripheral parts

ABSTRACT

[Problem to be Solved] There is provided automotive lamp peripheral parts excellent in the heat resistance, rigidity and fogging property. 
     [Solution] The automotive lamp peripheral part according to the present invention is obtained from a resin composition containing 70% by mass or more of a polyphenylene ether (A), and has a haze value of a glass plate of 1.0% or less after the glass plate is subjected to a following fogging test using an apparatus according to ISO 6452: 
     &lt;Fogging Test&gt; 
     60 g of a pellet or a molded article obtained from the resin composition is put in a glass-made sample bottle; the sample bottle is covered with a glass plate as a lid, and heated at 170° C. for 24 hours to thereby generate fogging on the glass plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.13/320,812, which is the National Stage of International Application No.PCT/JP2010/058664, filed May 21, 2010, the disclosure of which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates to automotive lamp peripheral parts.

BACKGROUND ART

As materials used for automotive lamp peripheral parts, mainlythermosetting resins such as unsaturated polyester resin BMCs (bulkmolding compounds) or aluminum have conventionally been used broadly.Although thermosetting resins such as unsaturated polyester resin BMCsare superior in the light weight to aluminum, since their specificgravities exceed 2.0, more weight reduction thereof is demanded.Thermosetting resins such as unsaturated polyester resin BMCs have alsoproblems including the complexity of postprocessing work of moldedarticles and the working environmental pollution due to dusts.Therefore, the conversion is progressing from thermosetting resins suchas unsaturated polyester resin BMCs and aluminum toward thermoplasticresins such as polyphenylene ether, polyether imide and highheat-resistive polycarbonate as materials used for automotive lampperipheral parts. In these applications, there are not a few cases wherea high heat resistance, and a high rigidity and the surface smoothnessof molded articles are required.

Polyphenylene ether resins have a variety of properties including beingexcellent in mechanical properties, electric properties, acidresistance, alkali resistance and heat resistance, and being low inwater absorption and good in dimensional stability. Hence, polyphenyleneether resins are broadly used as materials for household appliances, OAdevices, business machines, information equipment, automobiles and thelike.

A usual method of improving heat resistance and rigidity ofthermoplastic resins including polyphenylene ether resins is a method ofadding inorganic fillers such as glass fibers, carbon fibers, mica andtalc, but since the method remarkably damages the toughness, which theresins have intrinsically, and the surface appearance of moldedarticles, there are many applications in which the resins cannot beused.

There is now disclosed a technology regarding a reflecting plate for anautomotive lamp, which is prepared by using a polyphenylene ether-basedresin and which is excellent in heat resistance and hydrolysisresistance (for example, see Patent Document 1).

For a polyphenylene ether resin, there is disclosed a technology ofimparting a high rigidity and holding a toughness intrinsic to the resinand a surface gloss (for example, see Patent Document 2). The technologyis specifically one in which an inorganic filler surface treated with asilane compound and a thermoplastic elastomer modified with a specificfunctional group are added to a polyphenylene ether resin.

CITATION LIST Patent Document

-   Patent Document 1: Japanese Patent Laid-Open No. 5-320495-   Patent Document 2: WO 04/016692

SUMMARY OF INVENTION Problems to be Solved by the Invention

Since automotive lamp peripheral parts are used under a high-temperaturecondition near a lamp (heat source), a problem that arises is theoccurrence of fogging of a lens and the like by fogging gas components(outgas) emitted from resin materials constituting the parts.

Therefore, automotive lamp peripheral parts are required to have notonly a high heat resistance, a high rigidity and a surface smoothness ofmolded articles, but also an excellent fogging property under ahigh-temperature condition.

However, with respect to the resin compositions disclosed in thetechnical documents described above, no study has been made on thefogging property under a high-temperature condition; so the resincompositions are not necessarily preferable as a material for automotivelamp peripheral parts in some cases.

Then, it is an object of the present invention to provide automotivelamp peripheral parts having high heat resistance, rigidity and surfacesmoothness, and further being excellent in the aluminum-depositionappearance and the fogging property under a high-temperature condition.

Means for Solving the Problems

The present inventors have exhaustively studied to solve theabove-mentioned problems. As a result, it has been found that the use ofa resin composition containing a polyphenylene ether in a specific ratioand having a specific fogging property can solve the above-mentionedproblems, and this finding has led to the completion of the presentinvention.

That is, the present invention is as follows.

[1]

An automotive lamp peripheral part, being obtained from a resincomposition comprising 70% by mass or more of a polyphenylene ether (A),and

having a haze value of a glass plate of 1.0% or less after the glassplate is subjected to a following fogging test using an apparatusaccording to ISO 6452:

<Fogging Test>

60 g of a pellet or a molded article obtained from the resin compositionis put in a glass-made sample bottle; the sample bottle is covered witha glass plate as a lid, and heated at 170° C. for 24 hours to therebygenerate fogging on the glass plate.

[2]

The automotive lamp peripheral part according to [1], wherein the resincomposition further comprises 30% by mass or less of a styrene-basedresin (B).

[3]

The automotive lamp peripheral part according to [2], wherein thestyrene-based resin (B) is a styrene-based resin reinforced with norubber.

[4]

The automotive lamp peripheral part according to [2] or [3], wherein thestyrene-based resin (B) comprises a styrene-acrylonitrile resincomprising 5 to 15% by mass of acrylonitrile.

[5]

The automotive lamp peripheral part according to any one of [2] to [4],wherein 40% by mass or more in 100% by mass of the styrene-based resin(B) is a styrene-acrylonitrile resin comprising 5 to 15% by mass ofacrylonitrile.

[6]

The automotive lamp peripheral part according to any one of [1] to [5],wherein the resin composition further comprises 0.1 to 10% by mass of astyrene-based thermoplastic elastomer (C).

[7]

The automotive lamp peripheral part according to [6], wherein thestyrene-based thermoplastic elastomer (C) is a styrene-basedthermoplastic elastomer functionalized with a compound having an aminogroup.

[8]

The automotive lamp peripheral part according to any one of [1] to [7],wherein the resin composition further comprises 0.1 to 7% by mass of analkanesulfonic acid metal salt (D).

[9]

The automotive lamp peripheral part according to any one of [1] to [8],wherein the resin composition further comprises 5 to 25% by mass of akaolin clay (E); and

the kaolin clay (E) has an average primary particle diameter of 0.01 to1.0 μm.

[10]

The automotive lamp peripheral part according to [9], wherein the kaolinclay (E) has an average primary particle diameter of 0.01 to 0.5 μm.

[11]

The automotive lamp peripheral part according to [9] or [10], whereinthe proportion of the number of agglomerated particles of the kaolinclay (E) having a particle diameter of 2 μm or more accounts for lessthan 1%.

[12]

The automotive lamp peripheral part according to any one of [9] to [11],wherein the kaolin clay (E) is a waterwashed kaolin clay.

[13]

The automotive lamp peripheral part according to any one of [9] to [12],wherein the kaolin clay (E) is a kaolin clay dried by using a drier.

[14]

The automotive lamp peripheral part according to any one of [9] to [13],wherein the kaolin clay (E) is a kaolin clay dried by using a vacuumdrier heated at an interior temperature thereof of 150 to 200° C.

[15]

The automotive lamp peripheral part according to any one of [9] to [14],wherein the kaolin clay (E) has a residual volatile content (a weightloss proportion after drying at 200° C. for 3 hours by a vacuum drier)of 0.5% by mass or less.

[16]

The automotive lamp peripheral part according to any one of [9] to [15],wherein the kaolin clay (E) is a kaolin clay surface treated with asilane compound.

[17]

The automotive lamp peripheral part according to any one of [9] to [16],wherein the kaolin clay (E) is a kaolin clay surface treated with asulfur-based silane compound.

[18]

The automotive lamp peripheral part according to any one of [1] to [17],wherein the polyphenylene ether (A) has a reduced viscosity (measured at30° C. using a chloroform solvent) of 0.25 to 0.43 dL/g.

[19]

The automotive lamp peripheral part according to any one of [1] to [18],wherein an aluminum-deposited specular portion has a total reflectanceof 85% or more; and the aluminum-deposited specular portion has adiffusion reflectance of 3.0% or less.

[20]

The automotive lamp peripheral part according to [1] to [19], whereinthe automotive lamp peripheral part is one selected from the groupconsisting of automotive lamp lens holders, automotive lamp extensionsand automotive lamp reflectors.

Advantages of the Invention

The present invention can provide automotive lamp peripheral partshaving high heat resistance, rigidity and surface smoothness, andfurther being excellent in the aluminum-deposition appearance and thefogging property under a high-temperature condition.

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, a mode for carrying out the present invention (hereinafter,referred to as “present embodiment”) will be described in detail. Thepresent invention is not limited to the following embodiment, and may becarried out by being changed and modified variously within the gist.

<<Automotive Lamp Peripheral Part>>

The automotive lamp peripheral part according to the present embodimentis obtained from a resin composition comprising 70% by mass or more of apolyphenylene ether (A), and has a haze value of a glass plate of 1.0%or less after the glass plate is subjected to the following fogging testusing an apparatus according to ISO 6452. The haze value of the glassplate is preferably 0.8% or less, and more preferably 0.5% or less.

<Fogging Test>

60 g of a pellet or a molded article obtained from the resin compositiondescribed above is put in a glass-made sample bottle; the sample bottleis covered with a glass plate as a lid, and heated at 170° C. for 24hours to thereby generate fogging on the glass plate.

If the haze value of the glass plate is in the range described above, anautomotive lamp peripheral part excellent in the fogging property can beobtained. As a result, the function of a lamp can be held for a longperiod.

In the present embodiment, the fogging property refers to a propertythat the fogging is caused on portions to which gas components (outgas)emitted when a resin composition is heated are adhered. A smaller hazevalue of a glass plate after being subjected to the fogging testdescribed above means a better fogging property.

Use of a resin composition containing a polyphenylene ether (A) in aspecific ratio and having a specific fogging property can provide anautomotive lamp peripheral part having high heat resistance and rigidityand further being excellent in the fogging property under ahigh-temperature condition.

A molding method in the case of manufacturing the automotive lampperipheral part by using the resin composition is not limited to thefollowing, but suitably includes, for example, injection molding,extrusion, vacuum molding and compression molding.

In the present embodiment, automotive lamp peripheral parts mean partsused near a lamp (heat source) under a high-temperature condition, andinclude, for example, automotive lamp lens holders, automotive lampextensions and automotive lamp reflectors.

The automotive lamp peripheral part according to the present embodimentis especially preferably one selected from the group consisting ofautomotive lamp lens holders, automotive lamp extensions and automotivelamp reflectors, from the viewpoint of being excellent in surfacesmoothness, hot rigidity and heat resistance and excellent in thefogging property at high temperatures.

Here, an automotive lamp lens holder refers to a cylindrical member tounify a reflector as a light reflecting part present behind a lightsource beam of an automotive lamp and a convex lens present aheadthereof. The automotive lamp lens holder needs particularly to have thefogging property, and a high heat resistance and a high hot rigidity.

An automotive lamp extension refers to a relatively large-sized lightreflecting part present between the reflector and a lamp front cover,and although it does not need to have as high a heat resistance asneeded for the reflector and the lens holder, it needs particularly tohave the fogging property, the aluminum-deposition appearance, the heatresistance, the molding flowability, and a low specific gravity.

The automotive lamp reflector is a light reflecting part nearest thelight source beam, and needs particularly to have the fogging property,a high heat resistance, a high hot rigidity, and the aluminum-depositionappearance.

In the automotive lamp peripheral part according to the presentembodiment, a total reflectance of an aluminum-deposited specularportion is preferably 85% or more, more preferably 88% or more, andstill more preferably 90% or more, from the viewpoint of a sufficientlight reflection. A diffusion reflectance of the aluminum-depositedspecular portion is preferably 3.0% or less, more preferably 2.0% orless, and still more preferably 1.0% or less, from the viewpoint of thesufficient light reflection.

In the present embodiment, the total reflectance and the diffusionreflectance are values measured by methods described in Examplesdescribed later.

Hereinafter, each constituting component of resin compositions used inthe present embodiment will be described in detail.

<Polyphenylene Ether (A)>

A polyphenylene ether (A) used in the present embodiment is preferably ahomopolymer or a copolymer having a repeating unit represented by thefollowing formula (1) (the following general formulae (1)[a] and (1)[b]are collectively referred to as “the formula (1)”), and the repeatingunit composed of the general formula (1)[a] or the general formula(1)[b].

In the above formula, R1, R2, R3, R4, R5 and R6 are each independentlypreferably a monovalent residue of an alkyl group having 1 to 4 carbonatoms, an aryl group having 6 to 12 carbon atoms, a halogen, hydrogen,or the like. Provided that the case where R5 and R6 are hydrogensimultaneously is excluded. A more preferable number of carbon atoms ofthe alkyl group is 1 to 3, and that of the aryl group is 6 to 8; andamong the monovalent residues, a more preferable one is hydrogen. Thenumbers of the repeating units in the above formula (1)[a] and the aboveformula (1)[b] are not especially limited since those vary depending onthe molecular distribution of the polyphenylene ether (A).

Examples of the homopolymer of the polyphenylene ether (A) may include,but are not limited to, poly(2,6-dimethyl-1,4-phenylene)ether,poly(2-methyl-6-ethyl-1,4-phenylene)ether,poly(2,6-diethyl-1,4-phenylene)ether,poly(2-ethyl-6-n-propyl-1,4-phenylene)ether,poly(2,6-di-n-propyl-1,4-phenylene)ether,poly(2-methyl-6-n-butyl-1,4-phenylene)ether,poly(2-ethyl-6-isopropyl-1,4-phenylene)ether,poly(2-methyl-6-chloroethyl-1,4-phenylene)ether,poly(2-methyl-6-hydroxyethyl-1,4-phenylene)ether andpoly(2-methyl-6-chloroethyl-1,4-phenylene)ether. Above all,poly(2,6-dimethyl-1,4-phenylene)ether is preferable from the viewpointof the easiness of availability of the raw materials, and theproccessability.

Examples of the copolymer of the polyphenylene ether (A) may include,but are not limited to, ones having a polyphenylene ether structure as amain structure, such as copolymers of 2,6-dimethylphenol and2,3,6-trimethylphenol, copolymers of 2,6-dimethylphenol and o-cresol,and copolymers of 2,3,6-trimethylphenol and o-cresol. Above all,copolymers of 2,6-dimethylphenol and 2,3,6-trimethylphenol arepreferable from the viewpoint of the easiness of availability of the rawmaterials, and the proccessability; and a copolymer of 90 to 70% by massof 2,6-dimethylphenol and 10 to 30% by mass of 2,3,6-trimethylphenol ismore preferable from the viewpoint of improving physical properties.

A polyphenylene ether (A) may contain other various types of phenyleneether units as partial structures within the limits not departing fromthe desired advantage for the present embodiment. Examples of aphenylene ether unit may include, but are not limited to, a2-(dialkylaminomethyl)-6-methylphenylene ether unit and a2-(N-alkyl-N-phenylaminomethyl)-6-methylphenylene ether unit, describedin Japanese Patent Laid-Open Nos. 01-297428 and 63-301222.

A small amount of diphenoquinone and the like may further be bonded inthe main chain of the polyphenylene ether. A polyphenylene ether maystill further be converted to a functionalized polyphenylene ether byreacting (modifying) a part or the whole of the polyphenylene ether withan acyl functional group and a functionalizing agent containing one ormore selected from the group consisting of carboxylic acids, acidanhydrides, acid amides, imides, amines, orthoesters, and hydroxy andcarboxylic acid ammonium salts.

In the resin composition used in the present embodiment, a content ofthe polyphenylene ether (A) is 70% by mass or more, preferably 75 to 95%by mass or more, and more preferably 80 to 90% by mass or more. Makingthe content of the polyphenylene ether CA) in the range described abovecan provide an automotive lamp peripheral part having high heatresistance, rigidity and surface smoothness, and further being excellentin the aluminum-deposition appearance and the fogging property under ahigh-temperature condition.

A reduced viscosity of the polyphenylene ether (A) is in the range ofpreferably 0.25 to 0.55 dl/g, more preferably 0.25 to 0.50 dl/g,especially preferably 0.25 to 0.43 dl/g, and further especiallypreferably 0.25 to 0.35 dL/g. The reduced viscosity is preferably 0.25dl/g or higher from the viewpoint of sufficient mechanical properties,and is preferably 0.55 dl/g or lower from the viewpoint of the moldingproccessability. In the present embodiment, the reduced viscosity refersto a value acquired from a measurement using a chloroform solvent at 30°C.

The residual volatile content of the polyphenylene ether (A) ispreferably 0.6% by mass or less from the viewpoint of improving thesurface appearance of an automotive lamp peripheral part. A morepreferable content thereof is 0.4% by mass or less. Here, thepolyphenylene ether (A) whose residual volatile content is 0.6% by massor less is not limited to the following, but can be suitablymanufactured, for example, by regulating the drying temperature and thedrying time after the polymerization of the polyphenylene ether. Thedrying temperature includes 40 to 200° C., and is preferably 80 to 180°C., and more preferably 120 to 170° C. The drying time includes 0.5 to72 hours, and is preferably 2 to 48 hours, and more preferably 6 to 24hours. In order to remove the residual volatile content of apolyphenylene ether (A) in a relatively short time, the drying needs tobe carried out at a high temperature. In such a case, in order toprevent the deterioration due to heat, drying in a nitrogen atmosphereor drying in a vacuum drier is suitable. In the present embodiment, theresidual volatile content is indicated as a proportion of a lost massafter drying for 3 hours in a vacuum drier at 200° C. (a proportion of alost mass to an original mass).

In order to reduce the residual volatile content of the polyphenyleneether (A) and make the residual volatile content in the range describedabove by the drying after the polymerization, the polymerization ispreferably carried out by previously using a polymerization solvent notadversely affecting the polymerization, almost not adversely affectingthe environment, and having a relatively low boiling point to be easilyvolatilized. Examples of the polymerization solvent may include, but arenot limited to, toluene. Describing more specifically, after apolyphenylene ether whose reduced viscosity is in the range describedabove has been polymerized by a well-known polymerization method, byfully drying the obtained polymer using a vacuum drier or the like, apolyphenylene ether whose residual volatile content is in the rangedescribed above can be manufactured. Alternatively, even if apolymerization solvent other than a preferable one described above isused, by carrying out the drying fully, a polyphenylene ether whoseresidual volatile content is in the range described above can bemanufactured.

<Styrene-Based Resin (B)>

The resin composition used in the present embodiment preferably contains30% by mass or less of a styrene-based resin (B) from the viewpoint ofimproving the molding proccessability. The content of the styrene-basedresin (B) in the resin composition is more preferably 1 to 25% by mass,and still more preferably 4 to 20% by mass.

The content of the styrene-based resin (B) in the range described aboveis likely to improve the melt flowability of the resin compositionwithout damaging the rigidity and the heat resistance of an automotivelamp peripheral part to the best and without reducing the foggingproperty under a high-temperature condition.

The styrene-based resin (B) used in the present embodiment is preferablya styrene-based resin reinforced with no rubber.

Here, the styrene-based resin reinforced with no rubber refers to asynthetic resin obtained by polymerizing a styrene-based compound or astyrene-based compound and a compound copolymerizable with thestyrene-based compound in the absence of a rubbery polymer, and means acompound represented by the following formula (2).

In the above formula, R is hydrogen, a lower alkyl group or a halogen; Zis one or more selected from the group consisting of a vinyl group,hydrogen, a halogen and a lower alkyl group; and p is an integer of 0 to5. In the above formula, the substituent(s) other than Z in the phenylgroup is hydrogen.

Specific examples represented by the above formula (2) may include, butare not limited to, styrene, α-methylstyrene, 2,4-dimethylstyrene,monochlorostyrene, p-methylstyrene, p-tert-butylstyrene andethylstyrene.

The compound copolymerizable with the styrene-based compound includesmethacrylate esters such as methyl methacrylate and ethyl methacrylate;unsaturated nitrile compounds such as acrylonitrile andmethacrylonitrile; and acid anhydrides such as maleic anhydride, and isused together with the styrene-based compound.

A particularly preferable styrene-based resin reinforced with no rubberis a styrene-based resin containing a styrene-acrylonitrile resincontaining 5 to 15% by mass of an acrylonitrile component.

The content of acrylonitrile in the styrene-acrylonitrile resin ispreferably 5 to 15% by mass, more preferably 5 to 12% by mass, and stillmore preferably 7 to 10% by mass, from the viewpoint of improving thesurface appearance of an obtained automotive lamp peripheral part andsecuring sufficient miscibility with the polyphenylene ether (A).

40% by mass or more of the styrene-acrylonitrile resin containing 5 to15% by mass of acrylonitrile is preferably contained in 100% by mass ofa styrene-based resin (B) from the viewpoint of improving a balancebetween the molding flowability and the heat resistance and improvingthe fogging property and the aluminum-deposition appearance of themolded article. The proportion of the styrene-acrylonitrile resin in thestyrene-based resin (B) is more preferably 40 to 70% by mass, still morepreferably 45 to 65% by mass, and especially preferably 45 to 60% bymass.

<Styrene-Based Thermoplastic Elastomer (C)>

The resin composition used in the present embodiment preferably contains0.1 to 10% by mass of a styrene-based thermoplastic elastomer (C) fromthe viewpoint of imparting the impact resistance and further improvingthe fogging property.

The styrene-based thermoplastic elastomer (C) refers to a blockcopolymer having a polystyrene block and a rubber intermediate block.Examples of the rubber intermediate block may include, but are notlimited to, polybutadiene, polyisoprene, poly(ethylene-butylene),polyethylene-propylene) and vinyl-polyisoprene. The rubber intermediateblock may be used singly or in combination of two or more.

An arrangement mode of the repeating units constituting the blockcopolymer may be of a linear type or of a radial type. A block structureconstituted of the polystyrene block and the rubber intermediate blockmay be any of two-block type, three-block type and four-block type.Above all, the block copolymer is preferably a block copolymer of athree-block linear type constituted of apolystyrene-polyethylene-butylene)-polystyrene structure from theviewpoint of being capable of sufficiently exhibiting the desiredadvantage for the present embodiment. The rubber intermediate block maycontain a butadiene unit in a range not exceeding 30% by mass.

In the resin composition used in the present embodiment, as thestyrene-based thermoplastic elastomer (C), use of a styrene-basedthermoplastic elastomer functionalized by introduction of a functionalgroup such as a carbonyl group and an amino group is preferable from theviewpoint of improving the surface appearance of an automotive lampperipheral part. Particularly in the resin composition used in thepresent embodiment, as the styrene-based thermoplastic elastomer (C),use of a styrene-based thermoplastic elastomer functionalized by acompound having an amino group (hereinafter, also described as“functionalized styrene-based thermoplastic elastomer”) is morepreferable.

The carbonyl group is introduced to the styrene-based thermoplasticelastomer (C) by modifying with an unsaturated carboxylic acid or afunctional derivative thereof. Examples of the unsaturated carboxylicacid or the functional derivative thereof may include, but are notlimited to, maleic acid, fumaric acid, itaconic acid, halogenated maleicacid, cis-4-cyclohexene-1,2-dicarboxylic acid andendo-cis-bicyclo[2,2,1]-5-heptene-2,3-dicarboxylic acid, and anhydrides,ester compounds, amido compounds and imide compounds of thesedicarboxylic acids, and further acrylic acid and methacrylic acid andester compounds and amide compounds of these monocarboxylic acids. Aboveall, preferable is maleic anhydride from the viewpoint of holding thesurface appearance of an automotive lamp peripheral part and impartingthe impact resistance.

The amino group is introduced by reacting an imidazolidinone compound, apyrrolidone compound or the like with the styrene-based thermoplasticelastomer (C).

In the resin composition used in the present embodiment, the content ofthe styrene-based thermoplastic elastomer (C) is 0.1 to 10% by mass,preferably 0.5 to 8% by mass, more preferably 1 to 6% by mass, and stillmore preferably 2 to 5% by mass. The content is preferably 0.1% by massor more from the viewpoint of imparting the impact resistance andimproving the fogging property, and is preferably 10% by mass or lessfrom the viewpoint of holding the rigidity.

<Alkanesulfonic Acid Metal Salt (D)>

The resin composition used in the present embodiment preferably contains0.1 to 7% by mass of an alkanesulfonic acid metal salt (D) from theviewpoint of imparting the molding flowability, imparting the heatresistance and the impact resistance to an automotive lamp peripheralpart, and improving the aluminum-deposition appearance of the automotivelamp peripheral part.

The alkanesulfonic acid metal salt (D) refers to a compound representedby the chemical formula: R—SO₃X (R: an alkyl group or an aryl group, X:an alkali metal or an alkaline earth metal). Among such alkanesulfonicacid metal salts, an alkanesulfonic acid metal salt having 8 to 20carbon atoms is preferable; that having 12 to 20 carbon atoms is morepreferable; and that having 12 to 16 carbon atoms is especiallypreferable. An alkanesulfonic acid metal salt having 8 or more carbonatoms is preferable from the viewpoint of the heat resistance,mechanical properties such as the impact resistance, and holding thefogging property of the automotive lamp peripheral part; and analkanesulfonic acid metal salt having 24 or less carbon atoms ispreferable from the viewpoint of proccessability such as extrusion andmolding.

The alkanesulfonic acid metal salt (D) is preferably a sodiumalkanesulfonate. Specific examples of the sodium alkanesulfonate mayinclude sodium dodecanesulfonate, sodium tetradecanesulfonate, sodiumhexadecanesulfonate, sodium octadecanesulfonate, sodiumdecylbenzenesulfonate, sodium dodecylbenzenesulfonate and sodiumtetradecylbenzenesulfonate. Above all, especially preferable are sodiumalkanebenzenesulfonates such as sodium decylbenzenesulfonate, sodiumdodecylbenzenesulfonate and sodium tetradecylbenzenesulfonate. Thesesodium alkanesulfonates may be used singly or as a mixture of two ormore.

Any of properties of the alkanesulfonic acid metal salt (D), such asbeing liquid, powdery, granular, flaky and particulate (pellet-shaped),can be used. Being particulate (pellet-shaped) is preferable from theviewpoint of the prevention of moisture absorption and thehandleability.

In the resin composition used in the present embodiment, the content ofthe alkanesulfonic acid metal salt (D) is 0.1 to 7% by mass, preferably0.5 to 5% by mass, and more preferably 1 to 3% by mass. The content ispreferably 0.1% by mass or more from the viewpoint of imparting themolding flowability to the resin composition, imparting the heatresistance and impact resistance to an automotive lamp peripheral part,and improving the aluminum-deposition appearance of the automotive lampperipheral part; and the content is preferably 7% by mass or less fromthe viewpoint of holding the fogging property of the automotive lampperipheral part.

<Kaolin Clay (E)>

The resin composition used in the present embodiment preferably contains5 to 25% by mass of a kaolin clay (E) having an average primary particlediameter of 0.01 to 1 μm from the viewpoint of imparting the heatresistance and the hot rigidity to an automotive lamp peripheral partand improving the fogging property thereof without reducing theappearance of the automotive lamp peripheral part.

The average primary particle diameter of the kaolin clay (E) ispreferably in the range of 0.01 to 0.5 μm, more preferably 0.05 to 0.5μm, and still more preferably 0.05 to 0.3 μm. In the resin compositionused in the present embodiment, the average primary particle diameter ofthe kaolin clay (E) is preferably 0.01 μm or larger from the viewpointof improving the rigidity; and the diameter is preferably 1 μm orsmaller from the viewpoint of holding the gloss and the surfacesmoothness of an automotive lamp peripheral part. In the presentembodiment, the average primary particle diameter is a value acquired bymeasurement by a laser light diffraction method.

In the resin composition used in the present embodiment, the kaolin clay(E) can be blended as it is, but is preferably used with the residualvolatile content made 1.0% by mass or less, more preferably 0.5% by massor less, and still more preferably 0.3% by mass or less, from theviewpoint of the handleability and improving the flame retardance of theresin composition.

The residual volatile content of the kaolin clay (E) as a product isusually 1.3 to 1.5% by mass, but can be reduced by being dried in adrier. In the case of reducing the residual volatile content by using adrier, the drying is preferably carried out by using a vacuum drier fromthe viewpoint of the drying efficiency. The drying temperature ispreferably in the range of 80 to 220° C., more preferably in the rangeof 120 to 200° C., and especially preferably in the range of 150 to 180°C. The drying at 80° C. or higher is preferable from the viewpoint ofthe drying efficiency; and the drying at 220° C. or lower is preferablefrom the viewpoint of holding the quality of the kaolin clay. The dryingtime is preferably in the range of 0.5 to 24 hours, more preferably inthe range of 1 to 12 hours, still more preferably in the range of 1 to 8hours, and especially preferably in the range of 2 to 6 hours. Thedrying time is preferably 0.5 hour or longer from the viewpoint ofsufficient drying; and the drying time is preferably 24 hours or shorterfrom the viewpoint of sufficiently holding the quality.

When the kaolin clay (E) is taken out from the drier, the kaolin clay(E) is preferably taken out at a temperature of 100° C. or lower. Thetemperature is more preferably 70° C. or lower, and still morepreferably 50° C. or lower. The taking-out is preferably carried out at100° C. or lower from the viewpoint of sufficiently holding the qualityof the kaolin clay.

The kaolin clay (E) is preferably a kaolin clay dried using a drier, andmore preferably a kaolin clay dried using a vacuum drier whose interioris heated at 150 to 200° C.

In the present embodiment, the value of the residual volatile content ofthe kaolin clay (E) is indicated as a proportion of a lost mass afterthe kaolin clay (E) is dried for 3 hours in a vacuum drier at 200° C.based on an original mass.

In the resin composition used in the present embodiment, the kaolin clay(E) is preferably a kaolin clay surface treated with a silane compoundfrom the viewpoint of holding the surface appearance of an automotivelamp peripheral part.

The silane compound used for the surface treatment of the kaolin clay(E) is one usually used in order to surface treat glass fillers, mineralfillers and the like.

Specific examples of the silane compound may include, but are notlimited to, vinylsilane compounds such as vinyltrichlorosilane,vinyltriethoxysilane and γ-methacryloxypropyltrimethoxysilane;epoxysilane compounds such as γ-glycidoxypropyltrimethoxysilane;sulfur-based silane compounds such asbis-(3-triethoxysilylpropyl)tetrasulfide andγ-mercaptopropyltrimethoxysilane; and aminosilane compounds such asγ-aminopropyltriethoxysilane and N-phenyl-γ-aminopropyltrimethoxysilane.The silane compounds may be used singly or in combination of two ormore. Preferable silane compounds are sulfur-based silane compounds, andmore preferable silane compounds are mercaptosilane compounds, from theviewpoint of the easiness of handleability as powder, and being capableof sufficiently holding the flame retardancy being a desired advantagefor the present embodiment.

In the resin composition used in the present embodiment, the kaolin clay(E) is preferably a waterwashed kaolin clay from the viewpoint ofholding the surface smoothness of an automotive lamp peripheral part,improving the rigidity and toughness thereof, and improving the foggingproperty thereof.

The waterwashed kaolin clay refers to one obtained by using a method(waterwashing method) in which the separation purification of a kaolinclay having a desired average primary particle diameter is carried outafter the kaolin clay as a raw material is dispersed in water. Bypurifying and bleaching the raw material by utilizing water, impuritiesare removed and the whiteness is enhanced. Further since the particlesize is regulated by waterwashing, the kaolin clay has a sharp particlesize distribution.

In a resin composition used in the present embodiment, the content ofthe kaolin clay (E) is preferably 5 to 25% by mass, more preferably 10to 25% by mass, and still more preferably 10 to 20% by mass. The contentis preferably 5% by mass or more from the viewpoint of improving therigidity of an automotive lamp peripheral part, improving the heatresistance thereof, and improving the fogging property thereof; and thecontent is preferably 25% by mass or less from the viewpoint ofsufficiently holding the surface appearance of the automotive lampperipheral part.

To the resin composition used in the present embodiment, as required,stabilizers such as an antioxidant, an ultraviolet absorbent and athermal stabilizer, a colorant, a release agent, and the like may beadded.

[Manufacturing Method of the Resin Composition]

A manufacturing method of the resin composition used in the presentembodiment includes, for example, a method in which each componentdescribed above is melted and kneaded. The condition of melting andkneading the each component in order to manufacture the resincomposition is not especially limited, but in the case of using a twinscrew extruder, suitably involves melting and kneading under thecondition of a cylinder temperature of 270 to 340° C., a screw rotationfrequency of 150 to 550 rpm, and a vent vacuum degree of 11.0 to 1.0kPa, from the viewpoint of obtaining a resin composition capable ofsufficiently exhibiting a desired advantage for the present embodiment.

For the manufacturing method of the resin composition used in thepresent embodiment, use of a twin screw extruder can prepare the resincomposition in large amounts and stably.

EXAMPLES

Hereinafter, the present embodiment will be described more specificallyby way of Examples and Comparative Examples, but the present embodimentis not limited to these Examples.

Measuring methods of physical properties and raw materials used inExamples and Comparative Examples are as follows.

[Measuring Method of Physical Properties]

1. Heat Distortion Temperature (HDT)

Heat distortion temperatures were measured using 0.64 cm-thick testspecimens fabricated from molded articles obtained in Examples 1 to 23and Comparative Examples 1 to 4 described below, and at a load of 18.6kg/cm².

With respect to the evaluation standard, a material exhibiting a highervalue of HDT was determined to be more advantageous in the aspect ofmaterial design of automotive lamp peripheral parts because the materialwas better in heat resistance.

2. Molding Flowability (SSP)

Short shot pressures (SSP) when 0.16 cm-thick strip test specimens (withgates at both ends) were obtained from resin compositions obtained inExamples 1 to 12 and Comparative Examples 1 to 3 described below weremeasured in gauge pressure.

With respect to the evaluation standard, a material exhibiting a lowergauge pressure was determined to be more advantageous in the aspect ofmaterial design of automotive lamp peripheral parts because the materialwas better in molding flowability.

3. Flexural Strength and Flexural Modulus

The flexural strengths and flexural moduli were measured at 23° C. using0.64 cm-thick test specimens fabricated from molded articles obtained inExamples 1 to 12 and Comparative Examples 1 to 3 described below,according to ASTM D790.

4. Specific Gravity

The specific gravities of resin compositions obtained in Examples 1 to12 and Comparative Examples 1 to 3 described below were measured usingan electronic specific gravimeter SD-200L, made by AlfaMirage Co., Ltd.

5. Fogging Property

Haze values of glass plates after being subjected to a fogging testdescribed below using pellets of resin compositions obtained in Examples1 to 23 and Comparative Examples 1 to 4 described below and beingcarried out by an apparatus according to ISO 6452 were measured using ahaze meter (model: NDH2000, made by Nippon Denshoku Industries Co.,Ltd.).

<Fogging Test>

60 g of pellets of each resin composition obtained in Examples 1 to 23and Comparative Examples 1 to 4 described below was put in a glass-madesample bottle. A glass plate as a lid was mounted on and covers themouth of the sample bottle so as to completely cover the mouth of thesample bottle. The sample bottle covered with the glass plate as a lidwas heated for 24 hours in an oven whose interior temperature was set at170° C. By heating, fogging was caused to be generated on the glassplate of the portion of the sample bottle covering the mouth thereof.

Also for 60 g of cut pieces of each molded article obtained in Examples1, 7, 11, 20, 22 and 23 described below, the haze value of a glass plateafter being subjected to the same fogging test as in the above wasmeasured using a haze meter (model: NDH2000, made by Nippon DenshokuIndustries Co., Ltd.).

Further for 60 g of pellets of each resin composition obtained inExamples 13 to 23 and Comparative Example 4 described below, the hazevalue of a glass plate after being subjected to the same fogging test asin the above was measured using a haze meter (model: NDH2000, made byNippon Denshoku Industries Co., Ltd.), except for setting the interiortemperature of the oven at 200° C. Usually, the lower the interiortemperature of the oven, the less the fogging of the glass plate and thelower the haze value.

With respect to the evaluation standard, a material exhibiting a lowerhaze value of the glass plate was determined to be better in the foggingproperty because generation of fogging due to outgas was less.

6. Hot Rigidity

The measurement of three-point flexural viscoelasticity (measurementcondition: a vibration frequency of 10 Hz and a temperature-rise rate of3° C./sec) was carried out using a 4 mm-thick and 10 mm-wide testspecimen fabricated from each molded article obtained in Examples 13 to23 and Comparative Example 4 described below and by a dynamicviscoelasticity analyzer (EPLEXOR®, made by Gabo Qualimeter TestanlargenGmbH in Germany), to determine a numerical value of the storage elasticmodulus E′ at 200° C.

With respect to the evaluation standard, a material exhibiting a highernumerical value of the storage elastic modulus E′ was determined to bemore advantageous in expanding the possibility of application thereof tovarious types of automotive lamp peripheral parts because the materialwas better in the hot rigidity.

7. Surface Smoothness (Average Surface Roughness Ra of a Molded Article)

The average surface roughness Ra of the center portion of a flat testspecimen of 50 mm×90 mm×2.5 mm thick fabricated using each moldedarticle obtained in Examples 1 to 23 and Comparative Examples 1 to 4described below was determined using a surface roughness tester(Surftest SJ-400®, made by Mitutoyo Corp.). An average value ofnumerical values measured in the flowing direction of molten resin ininjection molding and in the direction perpendicular to the flow wasdefined as an average surface roughness.

With respect to the evaluation standard, a material having an averagesurface roughness of 20 nm or less was determined to be advantageous inexpanding the possibility of application thereof to various types ofautomotive lamp peripheral parts because the material was excellent inthe surface smoothness.

8. Aluminum-Deposition Appearance (Determination: Visual Observation)

Aluminum deposition was carried out by a vacuum deposition method on aflat test specimen of 100 mm×100 mm×2 mm thick fabricated using eachmolded article obtained in Examples 1 to 23 and Comparative Examples 1and 3 described below. After the aluminum deposition, the test specimenwas heated for 24 hours in an oven at 150° C. The luminance feeling ofthe deposited surface of the test specimen after the heating wasvisually observed and determined as follows.

Δ: The entire deposited surface was whitish.

◯: The entire deposited surface was slightly whitish, but good.

⊚: The entire deposited surface had no whiteness, and was very good.

9. Total Reflectance and Diffusion Reflectance

The test specimen after being subjected to the aluminum deposition in 8described above was heated for 24 hours in an oven at 150° C. The totalreflectance (%) and the diffusion reflectance (%) of the depositedsurface of the test specimen after the heating were determined using areflectometer (HR-100®, made by Murakami Color Research Laboratory Co.,Ltd.).

With respect to the evaluation standard, a material having a highertotal reflectance and a lower diffusion reflectance was determined to bea material better in the light reflection.

10. Flame Retardancy

The flammability test was carried out using a 1.6 mm-thick test specimenfabricated from each molded article obtained in Examples 19 to 21described below according to UL-94 test for flammability.

With respect to the evaluation standard, a material exhibiting a shorterburning time was determined to be more advantageous in having higherversatility in regulations including the amount of a flame retardantadded according to applications.

[Raw Materials]

<I: Thermoplastic Resin (A)>

(I-1) A poly(2,6-dimethyl-1,4-phenylene)ether having a reduced viscosity(chloroform, 30° C.) of 0.40 dl/g was used (hereinafter, referred to as“I-1”).

(I-2) A poly(2,6-dimethyl-1,4-phenylene)ether having a reduced viscosity(chloroform, 30° C.) of 0.30 dl/g was used (hereinafter, referred to as“I-2”).

<II: Styrene-Based Resin (B)>

(II-1) A general purpose polystyrene (Styron 660®, made by Dow ChemicalCo. in US) was used (Hereinafter, referred to as “II-1”). The generalpurpose polystyrene was a polystyrene containing no rubber component,that is, a polystyrene reinforced with no rubber.

(II-2) A styrene-acrylonitrile resin prepared as follows was used(hereinafter, referred to as “II-2”).

A mixed liquid composed of 4.7 parts by mass of acrylonitrile, 3.3 partsby mass of styrene, 22 parts by mass of ethylbenzene, and 0.02 part bymass of t-butylperoxy-isopropyl carbonate was continuously fed to a 5L-volume well stirred reactor at a flow rate of 2.5 l/h to bepolymerized at 142° C. to thereby obtain a polymerized liquid.

The obtained polymerized liquid was continuously introduced to anextruder with a vent. The unreacted monomers and the solvent wereremoved from the polymerized liquid under the condition of 260° C. and40 Torr to obtain a polymer. The polymer was continuously cooled to besolidified, and finely cut to obtain a particulate styrene-acrylonitrileresin.

The styrene-acrylonitrile resin was analyzed for the composition by aninfrared absorption spectrometry, and revealed to contain 9% by mass ofan acrylonitrile unit and 91% by mass of a styrene unit, and have a meltflow rate of 78 g/10 min (according to ASTM D-1238, measured at 220° C.and a load of 10 kg).

<III: Styrene-Based Thermoplastic Elastomer (C)>

(III-1) Tuftec H1041® (made by Asahi Kasei Chemicals Corp.) was used(hereinafter, referred to as “III-1”).

(III-2) A styrene-based thermoplastic elastomer functionalized with acompound having an amino group and prepared as follows was used(hereinafter, referred to as “III-2”).

In a reactor with a stirrer whose atmosphere was replaced by a nitrogengas, cyclohexane was used as a solvent, and n-butyllithium was used as apolymerization initiator. A block copolymer was polymerized which had anumber-average molecular weight of 40,000, apolystyrene-polybutadiene-polystyrene structure containing 30% by massof styrene units and 38% of a 1,2-vinyl bond amount of butadiene unitsbased on the total bond amount of the butadiene units, and livinglithium ion structures at the polymer terminals. After the completion ofthe polymerization, 1,3-dimethyl-2-imidazolidinone in an amount of 1.5times the mol of lithium ions present in the polymer solution originatedfrom the n-butyllithium used was added and reacted at 95° C. for 10 min.A hydrogenation reaction was carried out by a method described in U.S.Pat. No. 4,501,857 to obtain a polymer having a hydrogenation ratio of81.6% based on the total bond amount of the butadiene units before thereaction. 0.3 g of 2,6-di-tert-butyl-p-crezol as a thermal degradationstabilizer based on 100 g of the polymer was added to the polymersolution after the hydrogenation reaction; and cyclohexane as a solventwas removed under heating. A styrene-based thermoplastic elastomer wasthus obtained which had a structure of polystyrene-hydrogenatedpolybutadiene-polystyrene, and in which secondary amines were added tothe polystyrene terminals.

<IV: Alkanesulfonic Acid Metal Salt (D)>

(IV-1) A sodium alkanesulfonate (HOSTAPUR SAS93®, made by Clariant JapanKK) was used (hereinafter, referred to as “IV-1”).

(IV-2) A sodium alkanebenzenesulfonate (AKS-518-2®, made by Takemoto Oil& Fat Co., Ltd.) was used (hereinafter, referred to as “IV-2”).

<V: Kaolin Clay (E)>

(V-1) A waterwashed kaolin clay not surface treated and having anaverage primary particle diameter of 0.3 μm (trade name: Polygloss 90®,KaMin LLC in US) was used (hereinafter, referred to as “V-1”).

In the present Example, the average primary particle diameter of akaolin clay was determined as follows: the kaolin clay was dispersed for10 min in a hexametaphosphoric acid solution by an ultrasonic cleaner;and the obtained dispersion liquid was set on a MicroTrack particle sizeanalyzer (MT-3000II®, made by Nikkiso Co., Ltd.) to determine theparticle size distribution, and the central particle diameter D50% ofthe particle size distribution was defined as an average primaryparticle diameter.

(V-2) A waterwashed kaolin clay surface treated with a mercaptosilanecompound and having an average primary particle diameter of 0.2 μm(trade name: Nucap 290®, made by J. M. Huber Corp. in US) was used(hereinafter, referred to as “V-2”).

(V-3) A waterwashed kaolin clay prepared by drying the (V-2) describedabove for 3 hours in a vacuum drier at 200° C. was used (hereinafter,referred to as “V-3”).

The residual volatile contents (weight loss proportions after drying for3 hours in a vacuum drier at 200° C.) were 1.3% by mass for (V-2) and0.3% by mass for (V-3).

Comparative Example 1

A high-heat resistant polycarbonate (PC-HT, APEC1800®, made by BayerMaterial Science AG) was dried for 3 hours in a 120° C-hot air drier,and thereafter molded by an injection machine (IS-80C, made by ToshibaMachine Co., Ltd., the cylinder temperature: 330° C., the metal dietemperature: 90° C.) to obtain molded articles. The molded articles weremeasured for each physical property as described above. The measurementresults are shown in Table 1 shown below.

Example 1

90 parts by mass of the polyphenylene ether (I-1), 5 parts by mass ofthe styrene-based resin (II-1) and 5 parts by mass of the styrene-basedresin (II-2) were fed to a twin-screw extruder (made by Werner &Pfleiderer Industrial Bakery Technologies, model No.: ZSK25, the numberof barrels: 10, having the screw pattern of the screw diameter: 25 mm,L/D=44, kneading discs L: two discs, kneading discs R: six discs, andkneading discs N: two discs) from the most upstream section thereof (topfeed), and melted and kneaded at a cylinder temperature of 320° C., at ascrew rotation frequency of 250 rpm and at a vent vacuum degree of 7.998kPa (60 Torr), to thereby obtain pellets of a resin composition.

The obtained pellets of the resin composition were dried for 3 hours ina 120° C-hot air drier, and thereafter molded by an injection machine(IS-80C, made by Toshiba Machine Co., Ltd., the cylinder temperature:330° C., the metal die temperature: 90° C.) to obtain molded articles.The molded articles correspond to automotive lamp peripheral parts. Themolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 1 shown below.

Example 2

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1) and20 parts by mass of the styrene-based resin (II-1) as raw materials. Theobtained molded articles were measured for each physical property asdescribed above. The measurement results are shown in Table 1 shownbelow.

Comparative Example 2

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 60 parts by mass of the polyphenylene ether (I-1), 20parts by mass of the styrene-based resin (II-1) and 20 parts by mass ofthe styrene-based resin (II-2) as raw materials. The obtained moldedarticles were measured for each physical property as described above.The measurement results are shown in Table 1 shown below.

Comparative Example 3

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 60 parts by mass of the polyphenylene ether (I-1), 20parts by mass of the styrene-based resin (II-1) and 20 parts by mass ofa high impact polystyrene being a rubber-reinforced polystyrene(hereinafter, also referred to as “HIPS”, PS6200®, Nova Chemicals Corp.in US) as raw materials. The obtained molded articles were measured foreach physical property as described above. The measurement results areshown in Table 1 shown below.

Example 3

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 19parts by mass of the styrene-based resin (II-1) and 1 part by mass ofthe styrene-based thermoplastic elastomer (III-1) as raw materials. Theobtained molded articles were measured for each physical property asdescribed above. The measurement results are shown in Table 1 shownbelow.

Example 4

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 17parts by mass of the styrene-based resin (II-1) and 3 parts by mass ofthe styrene-based thermoplastic elastomer (III-1) as raw materials. Theobtained molded articles were measured for each physical property asdescribed above. The measurement results are shown in Table 1 shownbelow.

Example 5

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 17parts by mass of the styrene-based resin (II-1) and 3 parts by mass ofthe styrene-based thermoplastic elastomer (III-2) as raw materials. Theobtained molded articles were measured for each physical property asdescribed above. The measurement results are shown in Table 1 shownbelow.

Example 6

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 18parts by mass of the styrene-based resin (II-1) and 2 parts by mass ofthe alkanesulfonic acid metal salt (IV-1) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 1 shown below.

Example 7

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 8parts by mass of the styrene-based resin (II-1), 9 parts by mass of thestyrene-based resin (II-2) and 3 parts by mass of the styrene-basedthermoplastic elastomer (III-1) as raw materials. The obtained moldedarticles were measured for each physical property as described above.The measurement results are shown in Table 1 shown below.

Example 8

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 5parts by mass of the styrene-based resin (II-1), 12 parts by mass of thestyrene-based resin (II-2) and 3 parts by mass of the styrene-basedthermoplastic elastomer (III-1) as raw materials. The obtained moldedarticles were measured for each physical property as described above.The measurement results are shown in Table 1 shown below.

Example 9

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 17parts by mass of the styrene-based resin (II-1) and 3 parts by mass ofthe styrene-based thermoplastic elastomer (III-1) as raw materials. Theobtained molded articles were measured for each physical property asdescribed above. The measurement results are shown in Table 1 shownbelow.

Example 10

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 8parts by mass of the styrene-based resin (II-1), 8 parts by mass of thestyrene-based resin (II-2), 3 parts by mass of the styrene-basedthermoplastic elastomer (III-1) and 1 part by mass of the alkanesulfonicacid metal salt (IV-1) as raw materials. The obtained molded articleswere measured for each physical property as described above. Themeasurement results are shown in Table 1 shown below.

Example 11

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 7parts by mass of the styrene-based resin (II-1), 8 parts by mass of thestyrene-based resin (II-2), 3 parts by mass of the styrene-basedthermoplastic elastomer (III-1) and 2 parts by mass of thealkanesulfonic acid metal salt (IV-1) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 1 shown below.

Example 12

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1), 7parts by mass of the styrene-based resin (II-1), 8 parts by mass of thestyrene-based resin (II-2), 3 parts by mass of the styrene-basedthermoplastic elastomer (III-1) and 2 parts by mass of thealkanesulfonic acid metal salt (IV-2) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 1 shown below.

Comparative Example 4

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 63 parts by mass of the polyphenylene ether (I-1), 7parts by mass of the styrene-based thermoplastic elastomer (III-2) and30 parts by mass of the kaolin clay (V-1) as raw materials. Transmissionelectron microscopic photographs of the obtained molded articles weretaken at 10,000 power; and particle diameters of 1,000 or more particlesof the kaolin clay were measured by the image analysis from thephotographs, and agglomerated particles of 2 μm or larger were observedin 1.4% in the whole. The obtained molded articles were measured foreach physical property as described above. The measurement results areshown in Table 2 shown below.

Example 13

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 97 parts by mass of the polyphenylene ether (I-1) and 3parts by mass of the kaolin clay (V-1) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 2 shown below.

Example 14

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 100 parts by mass of the polyphenylene ether (I-1) as araw material. The obtained molded articles were measured for eachphysical property as described above. The measurement results are shownin Table 2 shown below.

Example 15

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1) and20 parts by mass of the kaolin clay (V-1) as raw materials. The obtainedmolded articles were measured, as in Comparative Example 4, for theproportion which the kaolin clay agglomerated particles of 2 μm orlarger accounted for, and the proportion was 0.6% in the whole. Theobtained molded articles were measured for each physical property asdescribed above. The measurement results are shown in Table 2 shownbelow.

Example 16

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 80 parts by mass of the polyphenylene ether (I-1) and20 parts by mass of the kaolin clay (V-2) as raw materials. The obtainedmolded articles were examined, as in Comparative Example 4, for theproportion which the kaolin clay agglomerated particles of 2 μm orlarger accounted for, and no kaolin clay agglomerated particles of 2 μmor larger were observed at all. The obtained molded articles weremeasured for each physical property as described above. The measurementresults are shown in Table 2 shown below.

Example 17

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 75 parts by mass of the polyphenylene ether (I-1), 5parts by mass of the styrene-based thermoplastic elastomer (III-1) and20 parts by mass of the kaolin clay (V-2) as raw materials. The obtainedmolded articles were examined, as in Comparative Example 4, for theproportion which the kaolin clay agglomerated particles of 2 μm orlarger accounted for, and no kaolin clay agglomerated particles of 2 μmor larger were observed at all. The obtained molded articles weremeasured for each physical property as described above. The measurementresults are shown in Table 2 shown below.

Example 18

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 75 parts by mass of the polyphenylene ether (I-1), 5parts by mass of the styrene-based thermoplastic elastomer (III-2) and20 parts by mass of the kaolin clay (V-2) as raw materials. The obtainedmolded articles were examined, as in Comparative Example 4, for theproportion which the kaolin clay agglomerated particles of 2 μm orlarger accounted for, and no kaolin clay agglomerated particles of 2 μmor larger were observed at all. The obtained molded articles weremeasured for each physical property as described above. The measurementresults are shown in Table 2 shown below.

Example 19

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 95 parts by mass of the polyphenylene ether (I-1) and 5parts by mass of the styrene-based thermoplastic elastomer (III-2) asraw materials. The obtained molded articles were measured for eachphysical property as described above. The measurement results are shownin Table 2 shown below.

Example 20

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 83 parts by mass of the polyphenylene ether (I-1), 2parts by mass of the styrene-based thermoplastic elastomer (III-1) and15 parts by mass of the kaolin clay (V-2) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 2 shown below.

Example 21

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 83 parts by mass of the polyphenylene ether (I-1), 2parts by mass of the styrene-based thermoplastic elastomer (III-1) and15 parts by mass of the kaolin clay (V-3) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 2 shown below.

Example 22

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 82 parts by mass of the polyphenylene ether (I-1), 5parts by mass of the styrene-based thermoplastic elastomer (III-2) and13 parts by mass of the kaolin clay (V-2) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 2 shown below.

Example 23

Pellets of a resin composition were obtained, and molded articles wereobtained from the pellets of the resin composition as in Example 1,except for using 82 parts by mass of the polyphenylene ether (I-2), 5parts by mass of the styrene-based thermoplastic elastomer (III-2) and13 parts by mass of the kaolin clay (V-2) as raw materials. The obtainedmolded articles were measured for each physical property as describedabove. The measurement results are shown in Table 2 shown below.

TABLE 1 Com. Com. Com. Ex. 1 Ex. 1 Ex. 2 Ex. 2 Ex. 3 Ex. 3 Ex. 4 Ex. 5(Formulation) parts by mass PC-HT (APEC1800) 100 Polyphenylene Ether(I-1) 90 80 60 60 80 80 80 Styrene-based Resin (II-1) 5 20 20 20 19 1717 Styrene-based Resin (II-2) 5 20 HIPS (PS6200) 20 Styrene-basedThermoplastic Elastomer (III-1) 1 3 Styrene-based ThermoplasticElastomer (III-2) 3 Alkanesulfonic Acid Metal Salt (IV-1) AlkanesulfonicAcid Metal Salt (IV-2) Sum Total 100 100 100 100 100 100 100 100(Physical Properties) Heat Resistance (HDT) (° C.) 160 172 157 135 130157 160 162 Molding Flowability (SSP) (kg/cm²) 85 43 30 11 14 30 31 31Flexural Strength (MPa) 110 122 125 112 105 123 125 129 Flexural ElasticModulus (MPa) 2200 2480 2540 2530 2380 2540 2500 2550 Specific Gravity1.16 1.05 1.05 1.05 1.05 1.05 1.05 1.05 170° C. Fogging Property(sample: pellet, haze value) (%) 1.6 0.2 0.7 1.8 2.6 0.6 0.4 0.4 170° C.Fogging Property (sample: molded article, haze value) (%) — 0.2 — — — —— — Average Surface Roughness of Molded Article (nm) 8.47 4.35 8.92 3.6940.7 8.67 8.90 4.28 <Aluminum-Deposition Appearance> Visual Evaluation*◯ ⊚ ◯ — Δ ◯ ◯ ⊚ Total Reflectance (%) 88 90 89 — 84 89 88 90 DiffusionReflectance (%) 0.8 0.7 1.1 — 3.9 1.0 1.2 0.7 Ex. 6 Ex. 7 Ex. 8 Ex. 9Ex. 10 Ex. 11 Ex. 12 (Formulation) parts by mass PC-HT (APEC1800)Polyphenylene Ether (I-1) 80 80 80 80 80 80 80 Styrene-based Resin(II-1) 18 8 5 8 7 7 Styrene-based Resin (II-2) 9 12 17 8 8 8 HIPS(PS6200) Styrene-based Thermoplastic Elastomer (III-1) 3 3 3 3 3 3Styrene-based Thermoplastic Elastomer (III-2) Alkanesulfonic Acid MetalSalt (IV-1) 2 1 2 Alkanesulfonic Acid Metal Salt (IV-2) 2 Sum Total 100100 100 100 100 100 100 (Physical Properties) Heat Resistance (HDT) (°C.) 163 164 165 160 164 163 165 Molding Flowability (SSP) (kg/cm²) 27 2524 28 24 26 26 Flexural Strength (MPa) 122 125 125 123 125 125 130Flexural Elastic Modulus (MPa) 2560 2550 2550 2550 2500 2500 2740Specific Gravity 1.05 1.05 1.05 1.05 1.05 1.05 1.05 170° C. FoggingProperty (sample: pellet, haze value) (%) 0.9 0.2 0.2 0.2 0.2 0.3 0.1170° C. Fogging Property (sample: molded article, haze value) (%) — 0.2— — — 0.3 — Average Surface Roughness of Molded Article (run) 3.98 3.773.78 3.78 3.75 3.23 2.02 <Aluminum-Deposition Appearance> VisualEvaluation* ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ Total Reflectance (%) 94 91 91 92 92 94 95Diffusion Reflectance (%) 0.5 0.7 0.7 0.6 0.7 0.5 0.4 *Evaluation ofaluminum-deposition appearance: Δ: whitish over the entire depositedsurface, ◯: good (partially whitish), ⊚: very good

It was found as indicated in Table 1 that every molded article obtainedfrom the resin compositions of Examples 1 to 12 was better in thebalance between the heat resistance (HDT) and the molding flowability(SSP), the rigidity, the light weight and the fogging property, andbetter in the appearance after the aluminum deposition than the moldedarticle obtained from the resin composition of Comparative Example 1,and was better in the heat resistance and the fogging property than themolded articles obtained from the resin compositions of ComparativeExamples 2 and 3. It was also found as indicated in Examples 3, 4 and 5and Examples 7 to 9 that blending a styrene-based thermoplasticelastomer and a styrene-acrylonitrile resin containing a specific AN %could further improve the fogging property, and additionally, blending aspecific styrene-based thermoplastic elastomer, a styrene-acrylonitrileresin containing a specific AN % and an alkanesulfonic acid metal saltcould remarkably improve the aluminum-deposition appearance of moldedarticles. Therefore, it was found that molded articles obtained from theresin compositions of Examples 1 to 12 could suitably be used asautomotive lamp parts, particularly automotive lamp extensions andautomotive lamp reflectors.

TABLE 2 Com. Ex. 4 Ex. 13 Ex. 14 Ex. 15 Ex. 16 Ex. 17 Ex. 18 Ex. 19 Ex.20 Ex. 21 Ex. 22 Ex. 23 (Formulation) parts by mass Polyphenylene Ether(I-1) 63 97 100 80 80 75 75 95 83 83 82 Polyphenylene Ether (I-2) 82Styrene-based Thermoplastic 5 2 2 Elastomer (III-1) Styrene-basedThermoplastic 7 5 5 5 5 Elastomer (III-2) Kaolin Clay (V-1) 30 3 20Kaolin Clay (V-2) 20 20 20 15 13 13 Kaolin Clay (V-3) 15 Sum Total 100100 100 100 100 100 100 100 100 100 100 100 (Physical Properties) HeatResistance (HDT) (° C.) 181 191 190 196 196 192 192 187 191 196 189 189170° C. Fogging Property 0.0 0.0 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0(sample: pellet, haze value) (%) 170° C. Fogging Property (sample: — — —— — — — — 0.0 — 0.0 0.0 molded article, haze value) (%) 200° C. FoggingProperty 0.0 2.8 2.8 0.5 0.3 0.0 0.0 2.3 0.2 0.0 0.1 0.0 (sample:pellet, haze value) (%) Hot Rigidity (GPa) 3.42 1.74 1.66 3.32 3.30 2.993.05 1.40 2.52 2.60 2.04 2.37 Average Surface Roughness of 38.8 10.59.88 18.4 12.2 7.24 5.26 4.82 4.94 4.81 3.21 2.20 Molded Article (nm)<Aluminum-Deposition Appearance> Visual Evaluation* — Δ ◯ Δ Δ Δ ◯ ⊚ Δ-◯◯ ⊚ ⊚ Total Reflectance (%) — — 89 — — — 84 92 84 84 90 92 DiffusionReflectance (%) — — 1.0 — — — 1.6 0.6 1.9 1.7 0.8 0.6 <Flame Retardancy1.6 mm> average sec — — — — — — — 8 21 7 — — maximum sec — — — — — — —24 52 17 — — determination — — — — — — — V-1 HB V-1 — — *Evaluation ofaluminum-deposition appearance: Δ: whitish over the entire depositedsurface, ◯: good (partially whitish), ⊚: very good

It was found as indicated in Table 2 that every molded article obtainedform the resin compositions of Examples 13 to 23 was excellent in theheat resistance and the surface smoothness (average surface roughness)of the molded articles, and particularly blending a kaolin clay used inthe present embodiment could provide an excellent heat resistance (HDT)and further a much improved fogging property. Therefore, it was foundthat molded articles obtained from the resin compositions of Examples 13to 23 could suitably be used as automotive lamp peripheral parts,particularly automotive lamp lens holders and automotive lampreflectors.

The present patent application is based on the Japanese PatentApplication (Japanese Patent Application No. 2009-123731) filed on May22, 2009, the Japanese Patent Application (Japanese Patent ApplicationNo. 2009-123734) filed on May 22, 2009, the Japanese Patent Application(Japanese Patent Application No. 2009-225247) filed on Sep. 29, 2009,and the Japanese Patent Application (Japanese Patent Application No.2009-225253) filed on Sep. 29, 2009, the subjects of which areincorporated herein by reference.

INDUSTRIAL APPLICABILITY

Since the automotive lamp peripheral parts according to the presentinvention have high heat resistance and rigidity, and further anexcellent fogging property and the like, these can effectively be usedparticularly as automotive lamp lens holders, automotive lampextensions, and automotive lamp reflectors.

1. An automotive lamp peripheral part, being obtained from a resincomposition comprising 70 to 95% by mass of a polyphenylene ether (A)and 5 to 25% by mass of a kaolin clay (E) having an average primaryparticle diameter of 0.01 to 1.0 μm; and having a haze value of a glassplate of 1.0% or less after the glass plate is subjected to a followingfogging test using an apparatus according to ISO 6452: <Fogging Test> 60g of a pellet or a molded article obtained from the resin composition isput in a glass-made sample bottle; the sample bottle is covered with aglass plate as a lid, and heated at 170° C. for 24 hours to therebygenerate fogging on the glass plate.
 2. The automotive lamp peripheralpart according to claim 1, wherein the resin composition furthercomprises 1 to 25% by mass of a styrene-based resin (B).
 3. Theautomotive lamp peripheral part according to claim 2, wherein thestyrene-based resin (B) is a styrene-based resin reinforced with norubber.
 4. The automotive lamp peripheral part according to claim 1,wherein the resin composition further comprises 0.1 to 10% by mass of astyrene-based thermoplastic elastomer (C).
 5. The automotive lampperipheral part according to claim 4, wherein the styrene-basedthermoplastic elastomer (C) is a styrene-based thermoplastic elastomerfunctionalized with a compound having an amino group.
 6. The automotivelamp peripheral part according to claim 1, wherein the resin compositionfurther comprises 0.1 to 7% by mass of an alkanesulfonic acid metal salt(D).
 7. The automotive lamp peripheral part according to claim 1,wherein the kaolin clay (E) has an average primary particle diameter of0.01 to 0.5 μm.
 8. The automotive lamp peripheral part according toclaim 1, wherein a proportion of a number of agglomerated particles ofthe kaolin clay (E) having a particle diameter of 2 μm or more accountsfor less than 1%.
 9. The automotive lamp peripheral part according toclaim 1, wherein the kaolin clay (E) is a waterwashed kaolin clay. 10.The automotive lamp peripheral part according to claim 1, wherein thekaolin clay (E) is a kaolin clay dried by using a drier.
 11. Theautomotive lamp peripheral part according to claim 1, wherein the kaolinclay (E) is a kaolin clay dried by using a vacuum drier heated at aninterior temperature thereof of 150 to 200° C.
 12. The automotive lampperipheral part according to claim 1, wherein the kaolin clay (E) has aresidual volatile content (a weight loss proportion after drying at 200°C. for 3 hours by a vacuum drier) of 0.5% by mass or less.
 13. Theautomotive lamp peripheral part according to claim 1, wherein the kaolinclay (E) is a kaolin clay surface treated with a silane compound. 14.The automotive lamp peripheral part according to claim 1, wherein thekaolin clay (E) is a kaolin clay surface treated with a sulfur-basedsilane compound.
 15. The automotive lamp peripheral part according toclaim 1, wherein the polyphenylene ether (A) has a reduced viscosity(measured at 30° C. using a chloroform solvent) of 0.25 to 0.43 dL/g.16. The automotive lamp peripheral part according to claim 1, wherein analuminum-deposited specular portion has a total reflectance of 85% ormore; and the aluminum-deposited specular portion has a diffusionreflectance of 3.0% or less.
 17. The automotive lamp peripheral partaccording to claim 1, wherein the automotive lamp peripheral part is oneselected from the group consisting of an automotive lamp lens holder, anautomotive lamp extension and an automotive lamp reflector.